Method of manufacturing a fluid pressure reduction device

ABSTRACT

A method of custom manufacturing a fluid pressure reduction device for use in a process control valve. The method includes creating the fluid pressure reduction device using an additive manufacturing technique, which generally includes forming a body and forming a plurality of flow paths in the body. The body has an inner wall and an outer wall spaced radially outward of the inner wall. The flow paths are formed in the body between the inner wall and the outer wall of the body. Each of the flow paths includes an inlet aperture, an outlet aperture, and an intermediate section extending between the inlet and outlet apertures. At least a portion of the intermediate section extends in a substantially vertical direction that is substantially parallel to the longitudinal axis, such that the flow paths are able to utilize previously un-used space in the device.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. patent applicationSer. No. 15/899,173, filed Feb. 19, 2018, which claims the prioritybenefit of U.S. Patent Application No. 62/511,187, filed May 25, 2017.The entire disclosure of each of these applications is herebyincorporated by reference.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to fluid pressure reductiondevices, and, more particularly, to a method of manufacturing a devicethat more efficiently and effectively reduces fluid pressure in aprocess control system.

BACKGROUND

In process control systems, such as distributed or scalable processcontrol systems commonly found in chemical, petroleum, power generation,or other industrial processes, it is often necessary to reduce thepressure of a fluid. However, pressure reduction typically leads toincreased levels of unwanted noise and/or vibration. Thus, processcontrol systems often employ flow reduction devices that aim to reducefluid pressure in a manner that does not lead to increased levels ofnoise and/or vibration.

U.S. Pat. No. 6,935,370 (“the '370 patent”) illustrates severaldifferent examples of fluid pressure reduction devices each taking theform of a plurality of stacked disks that, when employed in a fluid flowcontrol valve, reduce the pressure of a fluid flowing therethrough. Oneexample, illustrated in FIG. 5 of the '370 patent, features a pluralityof stacked annular disks rotated relative to one another to create flowpaths 62 that each provide multi-stage pressure reduction. Each disk 60of the stack has a laser cut profile defining a horizontal, spiral flowpath 62 that extends from an inlet section 68, through an intermediatesection 70 formed of a series of flat leg portions and includingrestrictions 74, 76, and to an outlet section 72 having a largercross-sectional area than the inlet section 68. Another example,illustrated in FIG. 8 of the '370 patent, features an annular disk 130that defines intersecting fluid flow paths 136, 138 so that fluidflowing therein collides, thereby releasing energy and reducing fluidpressure.

SUMMARY

In accordance with a first exemplary aspect of the present invention, afluid pressure reduction device for use in a fluid flow control device.The fluid pressure reduction device includes a unitary body and aplurality of flow paths. The unitary body has an inner wall and an outerwall spaced radially outward of the inner wall, the unitary bodyextending along a longitudinal axis. The flow paths are defined betweenthe inner wall and the outer wall of the unitary body. Each of the flowpaths includes an inlet aperture, an outlet aperture, and anintermediate section extending between the inlet and outlet apertures.At least a portion of the intermediate section extends in a directionthat is substantially parallel to the longitudinal axis.

In accordance with a second exemplary aspect of the present invention, afluid pressure reduction device for use in a fluid flow control device.The fluid pressure reduction device includes a unitary body and aplurality of flow paths. The unitary body includes a central opening anda perimeter surrounding the central opening, the perimeter having a topend and a bottom end opposite the top end. The flow paths are defined inthe perimeter of the unitary body, each of the flow paths including aninlet aperture, an outlet aperture, and an intermediate sectionconnecting the inlet and outlet apertures. The intermediate sectionextends between a position proximate the bottom end of the body and aposition proximate the top end of the body.

In accordance with a third exemplary aspect of the present invention, amethod of manufacturing is provided. The method includes creating afluid pressure reduction device using an additive manufacturingtechnique. The creating includes: forming a body having an inner walland an outer wall spaced radially outward of the inner wall, the bodyextending along a longitudinal axis; and forming a plurality of flowpaths in the body between the inner wall and the outer wall of the body.Each of the flow paths includes an inlet aperture, an outlet aperture,and an intermediate section extending between the inlet and outletapertures, wherein at least a portion of the intermediate sectionextends in a direction that is substantially parallel to thelongitudinal axis.

In further accordance with any one or more of the foregoing first,second, and third exemplary aspects, a fluid pressure reduction deviceand/or a method of manufacturing may include any one or more of thefollowing further preferred forms.

In one preferred form, a substantial portion of the intermediate sectionextends in the direction.

In another preferred form, the unitary body has a length defined betweena top end and a bottom end of the unitary body, and at least the portionof the intermediate section extending in the vertical direction travelsat least a majority of the length of the unitary body.

In another preferred form, the inlet and outlet apertures are orientedalong an axis that is substantially perpendicular to the longitudinalaxis.

In another preferred form, a plurality of pressure restrictions aredefined in the intermediate section.

In another preferred form, the intermediate section includes a firstvertical portion connected to the inlet portion and substantiallyparallel to the longitudinal axis, a second vertical portion that isconnected to the outlet portion and substantially parallel to thelongitudinal axis, and a curved portion that connects the first andsecond vertical portions.

In another preferred form, the inlet and outlet apertures are positionedproximate a bottom end of the unitary body, and a curved portion of theintermediate section is positioned proximate a top end of the unitarybody.

In another preferred form, a first flow path and a second flow path ofthe plurality of flow paths share a common intermediate section.

In another preferred form, the intermediate section includes a firstvertical portion that is connected to the inlet section andsubstantially parallel to the longitudinal axis, a second verticalportion that is connected to the outlet section and substantiallyparallel to the longitudinal axis, and a plurality of intermediateapertures that connect the first and second vertical portions and aresubstantially perpendicular to the longitudinal axis.

In another preferred form, the inlet aperture has a first diameter, theintermediate apertures of the intermediate section each have a seconddiameter larger than the first diameter, and the outlet aperture has athird diameter larger than the second diameter.

In another preferred form, the perimeter is defined by an inner wall andan outer wall spaced radially outward of the inner wall, and the flowpaths are defined between the inner wall and the outer wall.

In another preferred form, the unitary body extends along a longitudinalaxis, and the intermediate section includes a first vertical portionthat is connected to the inlet aperture and substantially parallel tothe longitudinal axis, a second vertical portion that is connected tothe outlet section and substantially parallel to the longitudinal axis,and a curved portion that connects the first and second verticalportions.

In another preferred form, the inlet and outlet apertures are positionedproximate the bottom end of the unitary body, and a curved portion ofthe intermediate section is positioned proximate the top end of theunitary body.

In another preferred form, the unitary body extends along a longitudinalaxis, and the intermediate section includes a first vertical portionthat is connected to the inlet aperture and substantially parallel tothe longitudinal axis, a second vertical portion that is connected tothe outlet aperture and substantially parallel to the longitudinal axis,and a plurality of intermediate apertures that connect the first andsecond vertical portions and are substantially perpendicular to thelongitudinal axis.

In another preferred form, the inlet aperture has a first diameter, eachof the intermediate apertures has a second diameter larger than thefirst diameter, and the outlet aperture has a third diameter larger thanthe second diameter.

In another preferred form, the additive manufacturing technique includes3D printing.

In another preferred form, the act of forming the plurality of flowpaths in the body includes forming the intermediate section to include afirst vertical portion connected to the inlet section and beingsubstantially parallel to the longitudinal axis, a second verticalportion that is connected to the outlet section and being substantiallyparallel to the longitudinal axis, and a curved portion that connectsthe first and second vertical portions.

In another preferred form, the act of forming the plurality of flowpaths in the body includes forming the intermediate section to include afirst vertical portion that is connected to the inlet aperture andsubstantially parallel to the longitudinal axis, a second verticalportion that is connected to the outlet aperture and being substantiallyparallel to the longitudinal axis, and a plurality of intermediateapertures that connect the first and second vertical portions and aresubstantially perpendicular to the longitudinal axis.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of this invention which are believed to be novel are setforth with particularity in the appended claims. The invention may bebest understood by reference to the following description taken inconjunction with the accompanying drawings, in which like referencenumerals identify like elements in the several FIGS., in which:

FIG. 1 is a schematic diagram of one example of a process or methodaccording to the teachings of the present disclosure for manufacturing afluid pressure reduction device;

FIG. 2A is a perspective view of a first example of a fluid pressurereduction device manufactured according to the process of FIG. 1;

FIG. 2B is a cross-sectional view of the fluid pressure reduction deviceof FIG. 2A;

FIG. 2C is another cross-sectional view of the fluid pressure reductiondevice of FIG. 2A;

FIG. 2D is a front, plan view of the fluid pressure reduction device ofFIG. 2A, showing a plurality of flow paths but with the rest of thedevice removed for clarity;

FIG. 2E is a top, plan view of the fluid pressure reduction device ofFIG. 2A, showing a plurality of flow paths but with the rest of thedevice removed for clarity;

FIG. 3A is a perspective view of a second example of a fluid pressurereduction device manufactured according to the process of FIG. 1;

FIG. 3B is a cross-sectional view of the fluid pressure reduction deviceof FIG. 3A;

FIG. 3C is another cross-sectional view of the fluid pressure reductiondevice of FIG. 3A;

FIG. 3D is a cross-sectional view taken along line 3D-3D in FIG. 3C; and

FIG. 4 is a cross-sectional view of a third example of a fluid pressurereduction device manufactured according to the process of FIG. 1.

DETAILED DESCRIPTION

The present disclosure is generally directed to a method ofmanufacturing a device that more effectively reduces fluid pressure thanconventional fluid pressure reduction devices (e.g., the stacked disksdescribed above in connection with the '370 Patent) and, at the sametime, is easier and less costly to manufacture than such conventionalfluid pressure reduction devices. The method described herein utilizescutting edge manufacturing techniques, e.g., additive manufacturing, tofacilitate custom manufacturing of a fluid pressure reduction devicesuch that any number of different flow paths can be developed andincorporated into a unitary or single body, depending upon the givenapplication. Thus, the fluid pressure reduction device can, for example,include complex flow paths that utilize substantially the entire profileof the device (as opposed to conventional fluid pressure reductiondevices, which typically have a significant amount of unused, or dead,space), thereby maximizing (or at least enhancing) flow path lengthsand, in turn, maximizing (or at least enhancing) the pressure reductioncapabilities of the device.

FIG. 1 is a diagram of an example of a method or process 100 accordingto the teachings of the present invention. The method or process 100schematically depicted in FIG. 1 is a method or process of custommanufacturing a fluid pressure reduction device such as a valve trimcomponent (e.g., a valve cage). Like the conventional fluid pressurereduction devices described above (e.g., the stack of disks 100), fluidpressure reduction devices manufactured according to the method orprocess 100 are configured to reduce the pressure of the fluid flowingtherethrough, but, as described above, are easier and less costly tomanufacture than conventional fluid pressure reduction devices and are,at the same time, just as if not more effective as conventional fluidpressure reduction devices.

More specifically, the method 100 includes the act 104 of creating acustomized fluid pressure reduction device, using an additivemanufacturing technique, based on the given application. The additivemanufacturing technique may be any additive manufacturing technique orprocess that builds three-dimensional objects by adding successivelayers of material on a material. The additive manufacturing techniquemay be performed by any suitable machine or combination of machines. Theadditive manufacturing technique may typically involve or use acomputer, three-dimensional modeling software (e.g., Computer AidedDesign, or CAD, software), machine equipment, and layering material.Once a CAD model is produced, the machine equipment may read in datafrom the CAD file and layer or add successive layers of liquid, powder,sheet material (for example) in a layer-upon-layer fashion to fabricatea three-dimensional object. The additive manufacturing technique mayinclude any of several techniques or processes, such as, for example, astereolithography (“SLA”) process, a fused deposition modeling (“FDM”)process, multi-jet modeling (“MJM”) process, a selective laser sintering(“SLS”) process, an electronic beam additive manufacturing process, andan arc welding additive manufacturing process. In some embodiments, theadditive manufacturing process may include a directed energy laserdeposition process. Such a directed energy laser deposition process maybe performed by a multi-axis computer-numerically-controlled (“CNC”)lathe with directed energy laser deposition capabilities.

The act 104 of creating the customized fluid pressure reduction deviceincludes forming a unitary or single body (act 108) and forming aplurality of flow paths in the unitary or single body (act 112). Theunitary body can be made of one or more suitable materials, such as, forexample, stainless steel, aluminum, various alloys, and, by virtue ofbeing customizable, can be any number of different shapes and/or sizes.As an example, the unitary body may take the form of a hollow cylinderdefined by an inner wall and an outer wall spaced radially outward ofthe inner wall. The flow paths formed in the body are generallyconfigured to reduce the pressure of a fluid flowing therethrough. Asdiscussed above, the usage of additive manufacturing techniques tocustom manufacture the fluid pressure reduction device allows the flowpaths to be formed based upon the desired application. In other words,the flow paths are customizable. By virtue of being customizable, theflow paths can be unique and complex (as opposed to simple), have anynumber of different lengths, have any number of different sizes and/orshapes in cross-section, and/or be arranged in any number of differentpatterns. As a result, one or more of the flow paths may be formed toinclude or define multiple different pressure stages (e.g., a firstpressure stage and a second pressure stage where pressure is less thanthe pressure in the first pressure stage), one or more of the flow pathsmay be partially or even substantially non-horizontal (i.e., includevertical components), one or more of the flow paths can vary in shapeand/or size as the fluid passes therethrough, one or more of the flowpaths can vary from one or more other flow paths, the flow paths can bestaggered or offset from one another (either horizontally or vertically)throughout the unitary body, one or more of the flow paths can extendbetween a position proximate a top end of the unitary body and a bottomend of the unitary body (e.g., travel or extend a substantial portion ofthe length of the unitary body), such that virtually the entire profileof the device is utilized, or combinations thereof.

It will be appreciated that the act 104 (and the acts 108, 112) can beperformed any number of different times. The act 104 can, for example,be performed multiple times so as to create multiple fluid pressurereduction devices for use in a single process control valve, with eachfluid pressure reduction device created for a specific application. Theact 104 can, alternatively or additionally, be performed multiple timesso as to create fluid pressure reduction devices for use in multiplesimilar or different process control valves.

FIGS. 2A-2E illustrate a first example of a fluid pressure reductiondevice 200 custom manufactured using the method or process 100. Thefluid pressure reduction device 200 in this example takes the form of avalve cage that can be disposed in a valve body of a process controlvalve (e.g., a sliding stem valve). The fluid pressure reduction device200 has a single or unitary body 204 and a plurality of flow paths 208formed or defined in the unitary body 204 to reduce the pressure of afluid flowing through the body 204. As will be discussed in greaterdetail below, the flow paths 208 are formed in the unitary body 204 in amanner that utilizes virtually the entire profile of the device 200,thereby maximizing (or at least increasing) the lengths of the flowpaths 208 and, in turn, maximizing (or at least enhancing) the pressurereduction capabilities of the device 200.

As illustrated in FIGS. 2A-2C, the body 204 has a central opening 212and a substantially cylindrical perimeter 216 surrounding the centralopening 212. The central opening 212 extends along a centrallongitudinal axis 218 and is sized to receive a valve plug of theprocess control valve that is movably disposed therein to control fluidflow through the process control valve. The substantially cylindricalperimeter 216 is defined by an inner wall 220 (which in turn defines thecentral opening 212) and an outer wall 224 that is spaced radiallyoutward of the inner wall 220.

As illustrated, the flow paths 208 are formed in the perimeter 216between the inner and outer walls 220, 224, and are circumferentiallyarranged around the central opening 212. Each of the flow paths 208 hasa circular shape in cross-section and includes an inlet aperture 236, anoutlet aperture 240, and an intermediate section 244 extending betweenthe inlet and outlet apertures 236, 240.

The inlet apertures 236 are formed in and through the inner wall 220(and, thus, in direct fluid communication with the central opening 212),with each oriented along a first axis (e.g., first axis 226) that issubstantially perpendicular (e.g., exactly perpendicular) to thelongitudinal axis 218. The inlet apertures 236 of the flow paths 208 arearranged in a plurality of rows 228, with alternating rows 228 of inletapertures 236 staggered or offset from one another. For example, inletapertures 236 in row 228A are staggered or offset from inlet apertures236 in row 228B, which is adjacent row 228A. Staggering the inletapertures 236 in this manner helps to achieve a balanced fluid flowthroughout the fluid pressure reduction device 200, though it is notnecessary that the inlet apertures 236 be staggered in this manner (orat all).

The outlet apertures 240 are formed in and through the outer wall 224,with each oriented along a second axis (e.g., second axis 246) that issubstantially co-axial, if not exactly co-axial, with the first axis(e.g., the first axis 226) (and thus substantially perpendicular, if notexactly perpendicular, to the longitudinal axis 218). The outletapertures 240 are, like the inlet apertures 236, arranged in a pluralityof rows 247, with alternating rows 247 of outlet apertures 240 staggeredor offset from one another in a similar manner as the alternating rows228 of inlet apertures 236. In other examples, however, the outletapertures 240 can be staggered or offset in a different manner (e.g.,from one another, from the inlet apertures 236) or not at all.

The intermediate sections 244 in this example are U-shaped and extendfrom a position proximate a bottom end 248 of the body 204 (where thesections 244 are connected to the inlet apertures 236, respectively),upward within the perimeter 216 toward a top end 252 of the body 204,and back downward to a position proximate the bottom end 248 (where thesections 244 are connected to the outlet apertures 240, respectively).In other words, the intermediate sections 244 of each flow path 208sweep or travel upward and back downward, i.e., 180 degrees. Thus, asillustrated, each intermediate section 244 has a first vertical portion256, e.g., a vertical chamber, that is connected to the respective inletaperture 236 and is substantially parallel to the longitudinal axis 218,a second vertical portion 260, e.g., a vertical chamber, that isconnected to the respective outlet aperture 240 and is substantiallyparallel to the longitudinal axis 218, and a curved portion 264, e.g., acurved chamber, located above the inlet and outlet apertures 236, 240,which connects the first and second vertical portions 256, 260 to oneanother.

So arranged, a substantial portion of the intermediate section 244 ofeach of the flow paths 208 is oriented in a substantially verticaldirection (i.e., substantially parallel to the longitudinal axis 218),if not an exactly vertical direction (i.e., exactly perpendicular to thelongitudinal axis 218). And because in this example the intermediatesection 244 comprises a substantial portion of each of the flow paths208, a substantial portion of each of the flow paths 208 in this exampleis oriented in the substantially vertical direction (or exactly verticaldirection). In other examples, however, this need not be the case. Insome examples, a greater portion of the intermediate section 244 can beoriented in a non-vertical direction, e.g., angled relative to thelongitudinal axis 218. Alternatively or additionally, the inlet andoutlet apertures 236, 240 may comprise a greater portion of each of theflow paths 208, such that the intermediate section 244 comprises amajority, but not substantial, portion of each of the flow paths 208.

Each intermediate section 244 in this example also includes a pluralityof pressure restrictions 268, each formed by narrowing the intermediatesection 244, for the purpose of producing additional pressure reductionby staging. In the illustrated example, each intermediate section 244includes four pressure restrictions 268 spaced apart from one anotherthroughout the length of the intermediate section 244. In otherexamples, more or less pressure restrictions 268 can be utilized (toproduce more or less pressure reduction).

It will be appreciated that the intermediate sections 244 of differentflow paths 208 (and more particularly the curved portions 264 of thosesections 244) will extend or travel upward to different points withinthe perimeter 216. In other words, some intermediate sections 244 willbe positioned closer to the top end 252 of the body 204 than otherintermediate sections 244. As an example, the intermediate section 244of flow path 208A extends to a position that is higher, i.e., closer tothe top end 252 of the body 204, than the intermediate section 244 offlow path 208B. The flow paths 208 therefore together span substantiallythe entire perimeter 216. In other words, the flow paths 208 are formedthroughout the perimeter 216, from the bottom end 248 to the top end 252of the body 204, thereby maximizing the lengths of the flow paths 208 byleaving little, if any, un-used upper dead space in the fluid pressurereduction device 200 (unlike conventional fluid pressure reductiondevices).

It will also be appreciated that one or more intermediate sections 244can vary in length from one or more other intermediate sections 244,such that one or more flow paths 208 are longer (or shorter) than one ormore other flow paths 208. This allows for variable pressure reductionwithin the pressure reduction device 200, with longer flow paths 208configured to reduce fluid pressure to a greater degree than the otherflow paths 208. As an example, the flow paths 208A, 208B, which haveinlet and outlet apertures 236, 240, respectively, formed closer to thebottom end 248 than the inlet and outlet apertures 236, 240 of flowpaths 208C, 208D, can be formed to be longer than the flow paths 208C,208D so as to effectively accommodate greater pressure changes that mayoccur as the valve plug of the process control valve first begins tomove to the open position (not shown), exposing the inlet aperture 236of the flow paths 208A, 208B. As the valve plug opens further, exposingadditional flow paths 208 like the flow paths 208C, 208D, shorter flowpaths may be utilized, as lesser changes in pressure need to beaccommodated. At the same time, these additional, shorter flow pathseffectively manage any differential pressure changes.

In other examples, the inlet aperture 236 of each of the flow paths 208can be formed in and through the outer wall 224 (instead of the innerwall 220), and the outlet aperture 240 of each of the flow paths 208 canbe formed in and through the inner wall 220 (instead of the outer wall224), such that fluid flows in the opposite direction (from outerdiameter to inner diameter) through the fluid pressure reduction device200. Moreover, in other examples, the intermediate section 244 of eachof the flow paths 208 can vary in shape and/or size from those depictedin FIGS. 2A-2E. As an example, the intermediate sections 244 can includeone or more portions that extend downward, below the inlet and outletapertures 236, 240, such that the device 200 provides a flow downconfiguration (rather than a flow up configuration). Further, while theflow paths 208 in this example each have a constant diameter, the flowpaths 208 can, in other examples, have a variable diameter (e.g., bytapering the intermediate sections 244), thereby providing recovery areafor fluid flowing therethrough.

When the fluid pressure reduction device 200 is in operation (in a valvebody of a process control valve), and the valve plug is moved to apartially open position (exposing some of the inlet apertures 236) or afully open position (exposing all of the inlet apertures 236), fluidwill flow from the valve body into the exposed inlet apertures 236 ofthe flow paths 208 via the central opening 212. Fluid will then flowinto and through the intermediate sections 244 of the flow path 208. Asfluid travels or sweeps upward (via the first vertical portion 256),fluid drags across or along an outer profile of each intermediatesection 244 while gravity acts on the fluid, thereby reducing thevelocity of the fluid. Along the way, the fluid encounters the pressurerestrictions 268 in each intermediate section 244, which respectivelyfacilitate additional pressure reduction. The pressure of the fluid isthus reduced to a fluid pressure that is less than its initial fluidpressure. As fluid travels or sweeps back downward (via the secondvertical portions 260), fluid continues to drag across or along an outerprofile of the intermediate sections 244, thereby further reducing thevelocity of the fluid. The fluid again encounters pressure restrictions268 along the way, which facilitate additional pressure reduction. Thepressure of the fluid is thus further reduced. The reduced pressurefluid then flows out of the pressure reduction device 200 (and into thevalve body) via the outlet apertures 240 of the flow paths 208. In thismanner, the device 200 reduces the pressure of the fluid flowingtherethrough (and thus through the process control valve). However, byemploying complex flow paths 208 that utilize substantially the entireprofile of the device 200 to do so, the device 200 more effectivelyreduces fluid pressure than conventional fluid pressure reductiondevices.

FIGS. 3A-3D illustrate a second example of a fluid pressure reductiondevice 300 custom manufactured using the method or process 100. Thefluid pressure reduction device 300 in this example also takes the formof a valve cage that can be employed in a valve body of a processcontrol valve (e.g., a sliding stem valve). The fluid pressure reductiondevice 300 is a stage-wise pressure reduction device that has a singleor unitary body 304 and a plurality of flow paths 308 formed or definedin the unitary body 304 to reduce the pressure of a fluid flowingthrough the body 304. As with the flow paths 208, the flow paths 308 areformed in the unitary body 304 in a manner that utilizes virtually theentire profile of the device 300, thereby maximizing (or at leastincreasing) the lengths of the flow paths 308 and, in turn, maximizing(or at least enhancing) the pressure reduction capabilities of thedevice 300.

As illustrated in FIGS. 3A, 3B, and 3C, the body 304 has a centralopening 312 and a substantially cylindrical perimeter 316 surroundingthe central opening 312. The central opening 312 extends along a centrallongitudinal axis 318 and is sized to receive a valve plug of theprocess control valve that is movably disposed therein to control fluidflow through the process control valve. The substantially cylindricalperimeter 316 is defined by an inner wall 320 (which in turn defines thecentral opening 312) and an outer wall 324 that is spaced radiallyoutward of the inner wall 320.

As best illustrated in FIGS. 3A-3D, the flow paths 308 are formed in theperimeter 316 between the inner and outer walls 320, 324, and arecircumferentially arranged around the central opening 312. Each of theflow paths 308 has a variable shape in cross-section defined in part byan inlet aperture 336 and an outlet aperture 340.

The inlet apertures 336 are formed in and through the inner wall 320(and, thus, in direct fluid communication with the central opening 212),with each oriented along a first axis (e.g., first axis 326) that issubstantially perpendicular (e.g., perpendicular) to the longitudinalaxis 318. The inlet apertures 336 are arranged in a plurality of rows328 and a plurality of columns 329, with alternating rows 328 of inletapertures 336 staggered or offset from one another and alternatingcolumns 329 of inlet apertures 336 staggered or offset from one another.For example, inlet apertures 336 in row 328A are staggered or offsetfrom inlet apertures 336 in row 328B, which is adjacent row 328A, andinlet apertures 336 in column 329A are staggered or offset from inletapertures 336 in column 329B, which is adjacent column 329A. Asdiscussed above, staggering the inlet apertures 336 in this manner helpsto achieve a balanced fluid flow throughout the fluid pressure reductiondevice 300, though it is not necessary that the inlet sections 336 bestaggered in this manner (or at all).

The outlet apertures 340 are formed in and proximate the outer wall 324,with each oriented along a second axis (e.g., second axis 346) that issubstantially parallel to but spaced from the first axis 326 (and thussubstantially perpendicular to the longitudinal axis 318). The outletapertures 340 are, like the inlet apertures 336, arranged in a pluralityof rows 345 and a plurality of columns 347 (best seen in FIG. 3D). Whilethe alternating columns 347 are staggered or offset from one another ina similar manner as the alternating columns 329, the alternating rows345 are staggered or offset from one another in a different manner thanthe alternating rows 328. As illustrated in FIGS. 3B and 3C, thealternating rows 345 of outlet apertures 340 are spaced further apartfrom one another than the alternating rows 328 of inlet apertures 336.Thus, as an example, the distance between outlet apertures 340 in row345A and outlet apertures 340 in row 345B is greater than the distancebetween inlet apertures 336 in the row 328A (which are respectivelyassociated with the outlet apertures 340 in row 345A) and inletapertures 336 in the row 328B (which are respectively associated withthe outlet apertures 340 in row 345B). As a result, the outlet apertures340 span a greater portion of the perimeter 316 of the body 304 than theinlet apertures 336, and, as such, are positioned closer to the top end352 of the body 304 than the inlet apertures 336 with which they areassociated. In the illustrated example, the outlet apertures 340 span aportion of the perimeter 316 that is twice as large as the portion ofthe perimeter 316 spanned by the inlet apertures 336, though thisdifference can vary.

In other examples, the inlet aperture 336 of each of the flow paths 308can be formed in and through the outer wall 324 (instead of the innerwall 320), and the outlet aperture 340 of each of the flow paths 308 canbe formed in and through the inner wall 320 (instead of the outer wall324), such that fluid flows in the opposite direction (from outerdiameter to inner diameter) through the fluid pressure reduction device300.

Each of the flow paths 308 is also defined by an intermediate section344 that extends between a respective one of the inlet apertures 336 anda respective one of the outlet apertures 340, and is shared with aplurality of other associated flow paths 308. In other words, the fluidpressure reduction device 300 includes a plurality of commonintermediate sections 344. In the illustrated example, each intermediateportion 344 serves as the common intermediate portion for flow paths 308including inlet apertures 336 in the same column 329 of inlet apertures336 and, in turn, all of the outlet apertures 340 in the column 347 ofoutlet apertures 340 respectively associated with that column 329 ofinlet apertures 336. As an example, intermediate portion 344A serves asthe common intermediate portion for the flow paths 308 including theinlet apertures 336 in column 329A and the outlet apertures 340 incolumn 347A (which is associated with column 329A). In other examples,however, the intermediate portions 344 can serve as common intermediateportions for differently associated flow paths 308.

As illustrated in FIGS. 3B and 3C, the intermediate portions 344 in thisexample are somewhat V-shaped and extend from a position immediatelyproximate a bottom end 348 of the body 304 (where each portion 344 isconnected to the inlet apertures 336 associated therewith), upwardwithin the perimeter 316 toward and to a position immediately proximatethe top end 352 of the body 304, and back downward to a positionimmediately proximate to the bottom end 348 (where each portion 344 isconnected to the outlet apertures 340 associated therewith). Asillustrated, each intermediate portion 344 has a first chamber 356 thatis connected to the respective inlet apertures 336 associated therewith,a second chamber 360 that is connected to the respective outlet section340 associated therewith, and a plurality of intermediate apertures 364that connect the first and second chambers 356, 360. While notillustrated herein, each intermediate portion 344 may optionally includeone or more pressure restrictions, e.g., the pressure restrictions 268described above, for the purpose of producing additional pressurereduction by staging.

The first chamber 356 in this example extends in a substantiallyvertical direction, but is oriented at a slight angle relative to thelongitudinal axis 318, such that the first chamber 356 is angledslightly radially outward, toward the outer wall 324, as the firstchamber 356 extends upward to the intermediate flow aperture 364. Thesecond chamber 360 in this example also extends in a substantiallyvertical direction, but is oriented at a slight angle relative to thelongitudinal axis 318, such that the second chamber 360 is angledslightly radially outward, toward the outer wall 324, as the secondchamber 360 extends downward away from the flow aperture 364. Asillustrated, the first and second chambers 356, 360 are tapered, whichhelps to promote a gradual fluid pressure reduction as the fluid flowstherethrough. In other examples, however, the first and second chambers356, 360 need not be so tapered.

The number of intermediate apertures 364 in each intermediate portion344 preferably corresponds to the number of inlet apertures 336 andoutlet apertures 340 associated with the respective intermediate portion344. Thus, as an example, when the intermediate portion 344A isassociated with eight inlet apertures 336 and eight outlet apertures340, as it is in FIGS. 3B and 3C, the intermediate portion 344Apreferably includes eight intermediate apertures 364. Each of theintermediate apertures 364 (in each intermediate portion 344) isoriented along a third axis (e.g., third axis 366) that is substantiallyparallel to but is spaced from the first and second axes (e.g., axes326, 346). In the illustrated example, the intermediate apertures 364 ineach intermediate portion 344 are all positioned above (i.e., closer tothe top end 352 of the body 304 than) the inlet apertures 336 and theoutlet apertures 340. In other examples, however, some or all of theintermediate apertures 364 can be positioned below or at the same levelas the inlet apertures 336 and/or the outlet apertures 340.

Preferably, each outlet aperture 340 will have a diameter that isgreater than a diameter of each of the intermediate flow apertures 364,which will in turn have a diameter that is greater than a diameter ofeach of the inlet apertures 336, such that the outlet apertures 340 havethe largest diameter. In one example, each outlet aperture 340 has adiameter of approximately 0.16 inches, each intermediate flow aperture364 has a diameter of approximately 0.14 inches, and each inlet aperturehas a diameter of approximately 0.12 inches. In other examples, however,the diameter of the outlet apertures 340 can be less than the diameterof the intermediate flow apertures 364 and/or the inlet apertures 336.Moreover, in other examples, one or more inlet apertures 336 can havedifferent diameters than one or more other inlet apertures 336 (e.g.,inlet apertures 336 closer to the bottom end 348 of the body 304 canhave a larger diameter than other inlet apertures 336), one or moreoutlet apertures 340 can have different diameters than one or more otheroutlet apertures 340 (e.g., outlet apertures 340 closer to the bottomend 348 of the body 304 can have a larger diameter than other outletapertures 340), and/or one or more intermediate apertures 364 can havedifferent diameters than one or more other intermediate apertures 364(e.g., intermediate apertures 364 closer to the bottom end 348 of thebody 304 can have a larger diameter than other intermediate apertures364).

With each intermediate portion 344 so arranged, a substantial portion ofthe intermediate portion 344 of each of the flow paths 308 is orientedin a substantially vertical direction. And because in this example theintermediate portion 344 comprises a substantial portion of each of theflow paths 308 (albeit one that is shared with other flow paths 308), asubstantial portion of each of the flow paths 308 in this example isoriented in the substantially vertical direction. In other examples,however, this need not be the case. In some examples, a greater portionof each intermediate section 344 can be oriented in a non-verticaldirection, e.g., angled relative to the longitudinal axis 318.Alternatively or additionally, the inlet and outlet apertures 336, 340may comprise a greater portion of each of the flow paths 308, such thatthe intermediate portions 344 comprise a majority, but not substantial,portion of each of the flow paths 308.

In addition to being substantially vertically oriented, the flow paths308 span substantially the entire perimeter 316. In other words, theflow paths 308 are formed throughout the perimeter 316, from the bottomend 348 to the top end 352 of the body 304, thereby maximizing thelengths of the flow paths 308 by leaving little, if any, un-used upperdead space in the fluid pressure reduction device 300 (unlikeconventional fluid pressure reduction devices).

When the fluid pressure reduction device 300 is in operation (in a valvebody of a process control valve), and the valve plug is moved to a fullyopen position, thereby exposing all of the inlet apertures 336, fluidwill flow from the valve body into the inlet apertures 336 of the flowpaths 308 via the central opening 312. Fluid will then flow into andthrough the common intermediate portions 344 shared by the flow paths308. As fluid travels upward (via the first chambers 356), fluid dragsacross or along an outer profile of the intermediate sections 344 whilegravity acts on the fluid, thereby reducing the velocity of the fluid.The pressure of the fluid is thus reduced to a fluid pressure that isless than its initial fluid pressure. The first chambers 356 of theintermediate portions 344 will then feed the fluid into the intermediateapertures 364, respectively, which in turn pass the fluid into thesecond chambers 360, respectively. As fluid travels back downward (viathe second chambers 360), fluid continues to drag across or along anouter profile of the intermediate portions 344, thereby further reducingthe velocity of the fluid. The pressure of the fluid is thus furtherreduced. The reduced pressure fluid then flows out of the pressurereduction device 300 (and into the valve body) via the outlet apertures340 of the flow paths 308. In this manner, the device 300 reduces thepressure of the fluid flowing therethrough (and thus through the processcontrol valve). However, by employing complex flow paths 308 thatutilize substantially the entire profile of the device 300 to do so, thedevice 300 more effectively reduces fluid pressure than conventionalfluid pressure reduction devices. Additionally, by increasing thediameters of the apertures in each flow path 308 as fluid travelsthrough the flow paths 308, additional pressure reduction is obtainedbeyond what is seen in conventional fluid pressure reduction devices.Furthermore, despite the fact that the outlet apertures 340 are spreadout to help achieve the desired pressure reduction, the fluid pressurereduction device 300 does not require the usage of a larger actuator(i.e., an actuator with a longer travel stroke), because of thepositioning of the inlet apertures 336 (which are not spread out in thesame way as the outlet apertures 340).

It will also be appreciated that the fluid pressure reduction describedabove occurs even when the valve plug is moved to a partially openposition, exposing one or more of the rows 328 of inlet apertures 336.In such a situation, fluid will flow from the valve body into theexposed inlet apertures 336 via the central opening 312. The fluid willthen travel through the pressure reduction device 300 in the mannerdescribed above, taking advantage of all of the associated intermediateapertures 364 and outlet apertures 340 even though less than all of theinlet apertures 336 are exposed.

FIG. 4 illustrates a third example of a fluid pressure reduction device400 custom manufactured using the method or process 100. The fluidpressure reduction device 400 is substantially similar to the fluidpressure reduction device 300, with common components referred to usingcommon reference numerals. However, instead of including a plurality ofcommon intermediate sections 344 (as the device 300 does), the device400 includes a single common intermediate section 444 that iscircumferentially arranged around the entire central opening 312 of thebody 304. The single common intermediate section 444 in this example isa curved plenum or area defined or formed between the inner walls 320,324 of the body 304 (and thus the inlet apertures 336 and the outletapertures 340, respectively). More particularly, the curved plenum orarea is defined between a first intermediate wall 480, positionedimmediately adjacent but radially outward of the inner wall 320 and influid communication with the inlet apertures 336, and a secondintermediate wall 484, positioned immediately adjacent but radiallyinward of the outer wall 324 and in fluid communication with the outletapertures 340. Thus, when fluid flows into the fluid pressure reductiondevice 400, it will flow into and through the single common intermediatesection 444, regardless of where that fluid enters the fluid pressurereduction device 400.

The single common intermediate section 444, which may also be referredto as a pressure recovery plenum, is beneficial in a number of ways.First, the single common intermediate section 444 allows the device 400to utilize the full annual area of the section 444 even when initiallyopening the valve plug. In other words, even as the valve plug firstbegins to move (either to a partially open or fully open position),thereby exposing one or more of the rows 328 of inlet apertures 336,fluid will flow into the single common intermediate section 444, takingfull advantage of the full recovery (and pressure reducing) area of theintermediate section 444. Second, the single common intermediate section444 allows the device 400 to fully utilize all of the outlet apertures440 regardless of how open the valve plug is (i.e., where the valve plugis relative to the valve seat). As an example, even when the valve plugis only at 10% travel (i.e., has traveled 10% of the distance needed tomove to its fully open position), such that two of the rows 328 of inletapertures 336 are exposed, fluid will flow into and through the singlecommon intermediate section 444, which then feeds all of the rows 345 ofoutlet apertures 340. In other words, all of the outlet apertures 340can be utilized for pressure reduction even though only some of theinlet apertures 336 have been exposed. Third, and finally, the singlecommon intermediate section 444 facilitates fluid interaction, as fluidthat has passed through one of the inlet apertures 336 will collide withfluid that has passed through the other inlet apertures 336, therebydissipating or absorbing kinetic energy in the fluid and stabilizing thefluid before entering the outlet apertures 340.

Preferred aspects of this invention are described herein, including thebest mode or modes known to the inventors for carrying out theinvention. Although numerous examples are shown and described herein,those of skill in the art will readily understand that details of thevarious aspects need not be mutually exclusive. Instead, those of skillin the art upon reading the teachings herein should be able to combineone or more features of one aspect with one or more features of theremaining aspects. Further, it also should be understood that theillustrated aspects are exemplary only, and should not be taken aslimiting the scope of the invention. All methods described herein can beperformed in any suitable order unless otherwise indicated herein orotherwise clearly contradicted by context. The use of any and allexamples, or exemplary language (e.g., “such as”) provided herein, isintended merely to better illuminate the aspect or aspects of theinvention, and do not pose a limitation on the scope of the invention.No language in the specification should be construed as indicating anynon-claimed element as essential to the practice of the invention.

The invention claimed is:
 1. A fluid pressure reduction device for usein a fluid flow control device, the fluid pressure reduction devicecomprising: a monolithic body having an inner wall and an outer wallspaced radially outward of the inner wall, the monolithic body extendingalong a longitudinal axis; and a plurality of flow paths defined betweenthe inner wall and the outer wall of the monolithic body, each of theflow paths comprising an inlet aperture, an outlet aperture, and anintermediate section extending between the inlet and outlet apertures,wherein at least a portion of the intermediate section extends in adirection that is substantially parallel to the longitudinal axis,wherein a first flow path and a second flow path of the plurality offlow paths share a common intermediate section, wherein the intermediatesection comprises a first vertical portion and a second verticalportion, the first vertical portion connected to the inlet aperture andoriented at a first angle relative to the longitudinal axis, and thesecond vertical portion connected to the outlet aperture and oriented ata second angle relative to the longitudinal axis, and wherein each ofthe first and second vertical portions is tapered.
 2. The fluid pressurereduction device of claim 1, wherein a majority of the intermediatesection extends in the direction.
 3. The fluid pressure reduction deviceof claim 1, wherein the monolithic body has a length defined from a topend of the monolithic body to a bottom end of the monolithic body, andwherein at least the portion of the intermediate section extending inthe vertical direction travels at least a majority of the length of themonolithic body.
 4. The fluid pressure reduction device of claim 3,wherein at least the portion of the intermediate section extending inthe vertical direction travels substantially entirely the length of themonolithic body.
 5. The fluid pressure reduction device of claim 1,wherein the inlet apertures of each of the flow paths span a firstportion of a perimeter of the monolithic body and the outlet aperturesof each of the flow paths span a second portion of the perimeter of themonolithic body, the second portion being greater than the firstportion.
 6. The fluid pressure reduction device of claim 1, wherein theinlet and outlet apertures of each of the flow paths are oriented alongan axis that is substantially perpendicular to the longitudinal axis. 7.The fluid pressure reduction device of claim 1, wherein the inletapertures of each of the flow paths extend along a respective firstinlet axis, and wherein the outlet apertures of each of the flow pathsextend along a respective first outlet axis that is parallel to butspaced from the respective first inlet axis.
 8. The fluid pressurereduction device of claim 1, further comprising a plurality ofintermediate apertures that connect the first and second verticalportions and are substantially perpendicular to the longitudinal axis.9. The fluid pressure reduction device of claim 8, wherein the inlet andoutlet apertures of each of the flow paths are positioned closer to abottom end of the monolithic body than a top end of the monolithic body,and wherein the plurality of intermediate apertures are positionedcloser to the top end of the monolithic body than the inlet and outletapertures of each of the flow paths.
 10. The fluid pressure reductiondevice of claim 1, wherein the first vertical portion comprises a firstchamber and the second vertical portion comprises a second chamberstructurally separate from the first chamber.
 11. A fluid pressurereduction device for use in a fluid flow control device, the fluidpressure reduction device comprising: a monolithic body extending alonga longitudinal axis and comprising a central opening and a perimetersurrounding the central opening, the perimeter having a top end and abottom end opposite the top end; a plurality of flow paths defined inthe perimeter of the monolithic body, each of the flow paths comprisingan inlet aperture, an outlet aperture, and an intermediate sectionconnecting the inlet and outlet apertures, wherein the intermediatesection extends between the bottom end and the top end, wherein a firstflow path and a second flow path of the plurality of flow paths share acommon intermediate section, wherein the inlet apertures of each of theflow paths span a first portion of the perimeter of the monolithic bodyand the outlet apertures of each of the flow paths span a second portionof the perimeter of the monolithic body, the second portion beinggreater than the first portion, wherein the intermediate sectioncomprises a plurality of intermediate apertures that are substantiallyperpendicular to the longitudinal axis, wherein the plurality ofintermediate apertures are positioned closer to the top end of themonolithic body than the inlet apertures of the plurality of flow paths,and wherein the intermediate section further comprises a first verticalportion and a second vertical portion, the first vertical portionconnected to the inlet apertures of each of the flow paths and orientedat a first non-zero angle relative to the longitudinal axis, and thesecond vertical portion connected to the outlet apertures of each of theflow paths and oriented at a second non-zero angle relative to thelongitudinal axis.
 12. The fluid pressure reduction device of claim 11,wherein the perimeter is defined by an inner wall and an outer wallspaced radially outward of the inner wall, and wherein the flow pathsare defined between the inner wall and the outer wall.
 13. The fluidpressure reduction device of claim 11, wherein the monolithic body has alength defined from the top end to the bottom end, and wherein theintermediate section spans at least a majority of the length of themonolithic body.
 14. The fluid pressure reduction device of claim 13,wherein the intermediate section substantially entirely spans the lengthof the monolithic body.
 15. The fluid pressure reduction device of claim11, wherein the inlet apertures of each of the flow paths extend along arespective first inlet axis, and wherein the outlet apertures of each ofthe flow paths extend along a respective first outlet axis that isparallel to but spaced from the respective first inlet axis.
 16. Thefluid pressure reduction device of claim 12, wherein the inlet andoutlet apertures of each of the flow paths are positioned closer to thebottom end than the top end.
 17. The fluid pressure reduction device ofclaim 12, wherein the first vertical portion comprises a first chamberand the second vertical portion comprises a second chamber structurallyseparate from the first chamber.
 18. The fluid pressure reduction deviceof claim 11, wherein each of the first and second vertical portions istapered.
 19. A method of manufacturing, comprising: creating a fluidpressure reduction device using an additive manufacturing technique, thecreating comprising: forming a monolithic body having an inner wall andan outer wall spaced radially outward of the inner wall, the monolithicbody extending along a longitudinal axis; and forming a plurality offlow paths in the monolithic body between the inner wall and the outerwall of the body, each of the flow paths comprising an inlet aperture,an outlet aperture, and an intermediate section extending between theinlet and outlet apertures, wherein at least a portion of theintermediate section extends in a direction that is substantiallyparallel to the longitudinal axis, wherein a first flow path and asecond flow path of the plurality of flow paths share a commonintermediate section, wherein the intermediate section comprises a firstvertical portion and a second vertical portion, the first verticalportion connected to the inlet aperture and oriented at a first anglerelative to the longitudinal axis, and the second vertical portionconnected to the outlet aperture and oriented at a second angle relativeto the longitudinal axis, and wherein each of the first and secondvertical portions is tapered.